Process for preparing polyarylates in the presence of a diphenyl ether

ABSTRACT

Described herein is a process for preparing polyarylates which comprises reacting a diester derivative of a dihydric phenol with an aromatic dicarboxylic acid in the presence of from about 10 to about 60 weight percent of a diphenyl ether compound at a temperature of from about 260° to about 350° C.

BACKGROUND OF THE INVENTION

This invention is directed to a process for preparing polyarylates having a reduced viscosity of from about 0.5 to greater than 1.0 dl/g, which process comprises reacting the diester derivative of a dihydric phenol with an aromatic dicarboxylic acid in the presence of from about 10 to about 60 weight percent, based on the weight of the polyarylate produced, of a diphenyl ether compound at a temperature of from about 260° to about 350° C.

Polyarylates are polyesters derived from a dihydric phenol, particularly 2,2-bis(4-hydroxyphenyl)propane also identified as Bisphenol-A, and an aromatic dicarboxylic acid, particularly mixtures of terephthalic and isophthalic acids. These polyarylates are high temperature, high performance thermoplastic polymers with a good combination of thermal and mechanical properties. They also have good processability which allows them to be molded into a variety of articles.

Many processes have been described in the literature for the preparation of polyarylates. One such process is the diacetate process. In the diacetate process, a dihydric phenol is converted to its diester derivative which is then reacted with an aromatic dicarboxylic acid to form the polyarylate. However, heretofore, the diacetate process has been carried out by several different methods as illustrated in the following U.S. patents:

In U.S. Pat. No. 2,595,343 issued May 6, 1952, an aromatic bisphenol is first reacted with acetic anhydride to form bisphenol diacetate which is then condensed with an aliphatic dicarboxylic acid to form a polyarylate by an acid interchange reaction. The condensation reaction is performed in the presence of an acid catalyst, such as para-toluenesulfonic acid, phosphoric acid or sulfuric acid. However, this acid exchange reaction does not yield an acceptable product when an aromatic dicarboxylic acid is substituted for the aliphatic acid.

U.S. Pat. No. 3,225,003 issued Dec. 21, 1965, describes the preparation of novel copolyesters by reacting hydroquinone diacetate with a mixture of hexahydroterephthalic acid and hexahydroisophthalic acid in the presence of a catalyst, such as sodium acetate, at a temperature of 230° C. The reaction is exemplified as being carried out in the presence of anhydrous sodium acetate catalyst and eutectic mixtures of biphenyl and diphenyl oxide (diphenyl ether) at 230° C. in three stages for a total reaction time of about 28 hours. Thus, this process requires catalyst, long reaction times and several steps.

U.S. Pat. No. 3,317,464, issued May 2, 1967, describes the preparation of linear aromatic polyesters by the polycondensation of diphenols, or their diacetates, with polynuclear aromatic dicarboxylic acids. The examples of this patent describe the preparation of the polyester using catalysts, such as mixtures of p-toluene sulphonic acid and antimony trioxide, or butyl orthotitanate, optionally in acetic acid. The reaction is carried out in a molten mixture of reagents and catalysts by heating these together under sub-atmospheric pressure. The patent states, but does not exemplify, that the reaction may be carried out in solution, in inert solvents, such as alpha-methyl-naphthalene, biphenyl or diphenyl oxide. Thus, this process requires catalysts as well as sub-atmospheric pressure conditions to form the polyesters.

U.S. Pat. No. 3,329,653 issued July 4, 1967 describes the preparation of high molecular weight linear condensation polymers, such as aromatic polyesters, aliphatic polyamides, and polycarbamides. These polymers are formed at or below the melting point of the polymer by carrying out the reaction while the reacting materials are suspended in an inert non-solvent medium, with a swelling agent for the condensation polymer which also needs to be present in the reaction medium. Example 7 of this patent describes the preparation of poly[2,2-bis(4-hydroxyphenyl)propane isophthalate] by heating a mixture of 780.9 g of the diacetate of Bisphenol-A, 415.3 g of isophthalic acid, 900 g. of Apco Inkol No. 0, 25 g of sulfolane swelling agent and 2.5 g of sodium methoxide catalyst. The reaction is held in reflux for 40 hours. The patent describes, as particularly effective swelling agents, sulfolane, diphenyl ether, and quinoline. Thus, this process requires the use of large quantities of a non-solvent, a catalyst, swelling agents as well as long reaction times.

U.S. Pat. No. 3,824,213 issued July 16, 1974, describes the preparation of halogenated aromatic polyesters by reacting in solution, an aliphatic carboxylic ester of a halogenated bisphenol, such as tetrachlorobisphenol-A with an aromatic acid mixture of terephthalic and isophthalic acids at a temperature of 220°-350° C., in the presence of a catalytically effective amount of a cobalt, nickel, or manganese salt of an aliphatic carboxylic acid. This patent describes that the esterification reaction may be conducted with said catalysts in a suitable solvent, such as a hydrocarbon, halogenated aliphatic or aromatic hydrocarbon or the like (i.e. a solvent which is inert under the reaction conditions employed). Specifically these solvents include diphenyl ether, benzophenone, dichloroethane and dichlorobenzene. This patent exemplifies that several prior art catalysts such as magnesium acetate are unsuitable for forming polyesters of acceptable inherent viscosities and that the particular cobalt, nickel or manganese salts, as described in this patent, are necessary to yield polyesters having an inherent viscosity of at least about 0.2, which is considered an acceptable viscosity in this patent.

U.S. Pat. No. 3,948,856 issued Apr. 6, 1976, describes an acid interchange polymerization process for producing an aromatic polyester by reacting substantially stoichiometric amounts of an aromatic diester with a dicarboxylic acid at a temperature of 220°-350° C., in a solvent, and in the presence of a catalyst, which is a mixture of a transition metal salt of a strong inorganic acid and a transition metal salt of an aliphatic carboxylic acid. The solvent includes diphenyl ether, halogenated diphenyl ether, diphenyl sulfone, benzophenone, polyphenyl ethers, etc.

U.S. Pat. Nos. 3,684,766 issued Aug. 15, 1972, and 3,780,148 issued Dec. 18, 1973, describe a variation of the diacetate process. In the patented processes, a prepolymer is formed from, for example, a diacetate, such as Bisphenol-A diacetate, and an aromatic acid, in the presence of a catalyst. The prepolymer so formed is then comminuted into small particles. These particles are then contacted with a crystallizing agent to crystallize the polyester. The crystallized polyester is heated in the presence of an inert gas and under reduced pressure to increase the inherent viscosity of the polyester. However, the processes described in these patents require multi-steps including the step of crystallizing the prepolymer.

U.S. Pat. No. 4,075,173 issued Feb. 21, 1978, describes the preparation of copolyesters by reacting an aromatic dicarboxylic acid, a diacetate of Bisphenol-A, and an acetate of p-hydroxybenzoic acid. Various processes for producing polyarylates by the reaction of Bisphenol-A and terephthalic and isophthalic acids are reviewed in this patent. The following process for producing polyarylates, identified as route (1), is described in column 2, of the patent: ##STR1##

This process is the diacetate process as described herein, or the "Acetate process" as defined in the patent.

Column 2 of the patent states:

"The route (1) is not desirable because the undesirable coloration and deterioration of polymer are particularly remarkable as disclosed in the abovementioned literature."

Further, column 3 of the patent states:

"On the other hand, the route (1), Acetate process, is economically advantageous because the materials used are cheap and the operation is simple. For example, diacetate of bisphenol-A, a monomer for Acetate process, is synthesized by merely reacting acetic anhydride and bisphenol-A. Consequently, it may be said that, if the fatal drawbacks of Acetate process, coloration and deterioration, are solved, Acetate process will become the most superior process."

Thus, the skilled workers in the field of polyarylate chemistry realize that the existing processes for producing polyarylates have one or more deficiencies, and that a need exists to develop a viable diacetate process for producing polyarylates.

In U.S. Pat. No. 4,075,173, a copolyester was prepared by the diacetate process by a solid-state polymerization of low molecular weight polymers without using crystallizing agents. The patentees state that their Acetate process is possible only when specific monomers are combined to form the prepolymer. These monomers are the diacetate of bisphenol-A, terephthalic acid and/or isophthalic acid and an acetate of p-hydroxybenzoic acid. The prepolymer is then converted to the desired high molecular weight polymer by solid state polymerization.

Thus, the diacetate processes for producing polyarylates by the procedures of the aforediscussed U.S. Patents, and as stated in U.S. Pat. No. 4,075,173, are generally unsuitable since they are either economically unattractive and/or produce a commercially unmarketable product. These prior art processes utilize catalysts, large amounts of solvents and generally long reaction times, high temperatures, as well as a complex series of steps, i.e. those as described in U.S. Pat. Nos. 3,684,766 and 3,780,148.

Therefore, a need exists for an economical and practical diacetate process for producing high molecular weight polyarylates.

In the diacetate process for producing polyarylates, problems exist which must be economically and practically solved in order to have a viable, economically attractive process. One problem when a diester derivative of a dihydric phenol is reacted with an aromatic dicarboxylic acid in the molten state is that sublimation of the diacid occurs. This disrupts the stoichiometry of the reaction and the polyarylate produced is not of acceptable molecular weight. To prevent sublimation of the diacid, several techniques have been developed. These include the use of large amounts of solvents together with a variety of catalysts and generally long reaction times in the polymerization process. However, these techniques are quite costly and do not provide an optimum process. Another problem when a diester derivative of a dihydric phenol is reacted with an aromatic dicarboxylic acid in the molten state is that the viscosity of the system increases dramatically towards the end of the reaction and therefore the reaction becomes diffusion controlled (the molecules are not close enough to insure rapid reaction) rather than kinetically controlled. Also, the polymer product is difficult to handle (i.e., removal from the reactor) due to this high viscosity.

Yet another problem in the production of polyarylates by the diacetate process is that a carboxylic acid is a by-product of the reaction of a diester derivative of a dihydric phenol with an aromatic dicarboxylic acid. In order to provide an efficient, economical process and a high molecular weight polyarylate, the acid, for example, the acetic acid has to be conveniently and efficiently removed.

It has now been discovered that polyarylate having a reduced viscosity of at least about 0.5 to greater than 1.0 dl/gm, can be efficiently and economically produced by a process which does not require the use of a catalyst or large amounts of solvent. The present process comprises reacting a diester derivative of a dihydric phenol with an aromatic dicarboxylic acid in the presence of from about 10 to about 60 weight percent, based on the polyarylate produced, of a diphenyl ether compound at a temperature of from about 260° to about 350° C.

The utilization of from about 10 to about 60 percent of a diphenyl ether compound in the diacetate process prevents sublimation of the aromatic dicarboxylic acid; thus producing polyarylates of acceptable molecular weight. Also, the diphenyl ether compound provides for better removal of the acetic acid by-product. Further, an additional benefit in using a diphenyl ether compound in the amounts indicated is that the viscosity of the system is decreased. This decrease in viscosity provides a faster reaction time since better mixing of the reactants occurs which allows the reaction to proceed under kinetic control. Additionally, by using the specified diphenyl ether, reaction times are relatively short so that a polyarylate is produced generally in less than 10 hours at the reaction temperatures and the polyarylates produced possess lighter color, as compared to those utilizing longer reaction times. Furthermore, the present process can be carried out at atmospheric pressure and therefore avoids the use of the costly equipment which is needed by the prior art processes which carry out the diacetate process under vacuum.

DESCRIPTION OF THE INVENTION

The present invention is directed to a process for the preparation of normally solid amorphous polyarylates having a reduced viscosity of from about 0.5 to greater than 1.0 dl/gm, which process comprises reacting a diester derivative of dihydric phenol with an aromatic dicarboxylic acid in the presence of from about 10 to about 60 weight percent, based on the weight of the polyarylate produced, of a diphenyl ether compound at a temperature of from about 260° to about 350° C.

The present process comprises reacting:

(a) at least one diester derivative of a dihydric phenol having the following formula: ##STR2##

wherein R is independently selected from an alkyl radical having from 1 to about 6 carbon atoms, preferably methyl, cycloalkyl having from 4 to about 7 carbon atoms, y is independently selected from alkyl groups of 1 to 4 carbon atoms, chlorine or bromine, z independently has a value of from 0 to 4, inclusive, and R' is independently selected from a divalent saturated aliphatic hydrocarbon radical, particularly alkylene or alkylidene radicals having from 1 to 8 carbon atoms, especially C(CH₃)₂, cycloalkylene or cycloalkylidene radicals having up to and including 9 carbon atoms, O, S, SO, SO₂, and CO, x is 0 or 1; and

(b) at least one aromatic dicarboxylic acid.

The diester derivative of the dihydric phenol is prepared by reacting a dihydric phenol with an acid anhydride derived from acids containing from 2 to 8 carbon atoms under conventional esterification conditions. The preferred acid anhydride is acetic anhydride. Generally, the dihydric phenol is reacted with the acid anhydride in the presence of an esterification catalyst, either in the presence or absence of a solvent.

The dihydric phenols that may be used in this invention include the following:

2,2-bis-(4-hydroxyphenyl)propane,

bis-(2-hydroxyphenyl)methane,

bis-(4-hydroxyphenyl)methane,

bis-(4-hydroxy-2,6-dimethyl-3-methoxyphenyl)methane,

1,1-bis-(4-hydroxyphenyl)ethane,

1,2-bis-(4-hydroxyphenyl)ethane,

1,1-bis-(4-hydroxy-2-chlorophenyl)ethane,

1,1-bis-(3-methyl-4-hydroxyphenyl)ethane,

1,3-bis-(3-methyl-4-hydroxyphenyl)propane,

2,2-bis-(3-phenyl-4-hydroxyphenyl)propane,

2,2-bis-(3-isopropyl-4-hydroxyphenyl)propane,

2,2-bis-(2-isopropyl-4-hydroxyphenyl)propane,

2,2-bis-(4-hydroxyphenyl)pentane,

3,3-bis-(4-hydroxyphenyl)pentane,

2,2-bis-(4-hydroxyphenyl)heptane,

1,2-bis-(4-hydroxyphenyl)-1,2-bis-(phenyl)-propane,

4,4'-(dihydroxyphenyl)ether,

4,4'-(dihydroxyphenyl)sulfide,

4,4'-(dihydroxyphenyl)sulfone,

4,4'-(dihyroxyphenyl)sulfoxide,

4,4'-(dihydroxybenzophenone),

hydroquinone, and

naphthalene diols.

These dihydric phenols may be used individually or in any combination which when reacted with an aromatic dicarboxylic acid produces polyarylate polymers that essentially do not crystallize during the reaction and recovery steps. The preferred dihydric phenol is 2,2-bis(4-hydroxyphenyl)propane.

The aromatic dicarboxylic acids that may be used in this invention include terephthalic acid, isophthalic acid, any of the naphthalene dicarboxylic acids and mixtures thereof, as well as alkyl substituted homologs of these carboxylic acids, wherein the alkyl group contains from 1 to about 4 carbon atoms, and acids containing other inert substituents such as halides, alkyl or aryl ethers, and the like. Preferably, mixtures of isophthalic and terephthalic acids are used. The isophthalic acid to terephthalic acid ratio in the mixture is about 20:80 to about 100:0, while the most preferred acid ratio is about 25:75 to about 50:50. Also, from about 0.5 to about 20 percent of aliphatic diacids containing from 2 to about 10 carbon atoms, such as adipic acid, sebacic acid, and the like may be additionally used in the polymerization reaction.

The dihydric phenols and aromatic dicarboxylic acids are selected so that the polyarylate produced remains in an essentially amorphous state during the polymerization reaction and recovery step.

The reaction of the diester derivative of a dihydric phenol with the aromatic dicarboxylic acid is carried out in the presence of from about 10 to about 60, preferably from about 25 to about 40, and most preferably, from about 30 to about 40 weight percent, based on the weight of the polyarylate produced, of a diphenyl ether (also known as diphenyl oxide) compound. The diphenyl ether compound may be substituted. These substituents are selected from alkyl groups, chlorine, bromine or any substituent which does not interfere with the polyarylate forming reaction or the reaction forming the diester derivative of the dihydric phenol. Additionally, the diphenyl ether compound may be used with up to 50 weight percent of other compounds, such as various biphenyls or any other compounds which do not interfere with the polyarylate forming reaction or the reaction forming the diester derivative of the dihydric phenol.

The amount of the diphenyl ether compound could vary during the polymerization reaction. For example, it may be advantageous to increase progressively the amount of diphenyl ether compound to maintain the reaction medium at about constant viscosity.

The reacton of the diester derivative of the dihydric phenol with the aromatic dicarboxylic acid is performed with these reactants present in the ratio of from about 0.85:1.00 to about 1.10:1.00, preferably from about 0.98:1.02 to about 1.02:0.98, diester derivative: aromatic dicarboxylic acid.

The process of this invention is carried out at a temperature of from about 260° to about 350° C. and preferably, from about 275° to about 295° C. The present process is generally conducted in an inert atmosphere (such as argon or nitrogen). The process is preferably carried out at atmospheric pressure although higher and lower pressures may be used. Obviously, at pressures higher than atmospheric pressure, higher temperatures will result.

The polymerization reaction is conducted for a period of time sufficient to produce a polyarylate having a reduced viscosity of at least about 0.5 to greater than 1.0 dl/gm, which time is generally less than about 10 hours. The reaction time is generally in the range of from about 4 hours to about 8 hours, depending on the particular polyarylate being prepared.

The polymerization reaction of this invention may be carried out batchwise or continuously and by using any apparatus desired. Moreover, the reactants may be added to the polymerization zone in any way or order desired as long as the polymerization takes place in the presence of from about 10 to about 60 weight percent of a diphenyl ether compound.

The diester derivative of the dihydric phenol may be formed, in situ, by adding the dihydric phenol together with the acid anhydride, an aromatic dicarboxylic acid and a diphenyl ether compound to the reactor and the reaction carried out in a single reaction zone under combined esterification and polymerization conditions as described above. Additionally, the diester derivative of the dihydric phenol may be first prepared and then an aromatic dicarboxylic acid and a diphenyl ether compound added directly to the same reaction vessel with the polymerization being carried out under the conditions described above.

The polyarylate polymer having a reduced viscosity of at least about 0.5 is recovered in its final form by methods well known to those in the art, such as by direct devolatilization in an extruder under conditions sufficient to remove the diphenyl ether compound, coagulation, spray drying, and the like.

The polyarylates may also be prepared by first forming a polyarylate prepolymer having a reduced viscosity of from about 0.1 to about 0.4 dl/gm, by reacting the diester derivative of a dihydric phenol with an aromatic dicarboxylic acid in the presence of a diphenyl compound under the conditions described previously, for a reaction time of about 3 hours. The polyarylate prepolymer is then heated at temperatures of from about 300 to about 350° C. to obtain a polyarylate having a reduced viscosity of from about 0.5 to greater than 1.0 dl/gm.

Alternatively, the polyarylate prepolymer may be added directly, after its formation, to a vented extruder wherein the molecular weight is increased to form a polymer having a reduced viscosity of from about 0.5 to greater than about 1.0 dl/gm. For example, the molecular weight of polyarylate prepolymer is increased in the extruder at a temperature of from about 320 to about 350° C., under a vacuum of about 0.3 to about 2 mm Hg and a residence time of from about 10 to about 30 minutes.

The process of this invention produces normally solid polyarylates having a reduced viscosity of from about 0.5 to greater than about 1.0, preferably from about 0.6 to about 0.8 dl/gm, as measured in chloroform (0.5 g/dl chloroform) or other suitable solvent at 25° C.

In those instances where the polyarylate is not soluble in chloroform, other solvents known in the art such as parachlorophenol, phenol/tetrachoroethane (60/40), etc may be used. Reduced viscosities of the polyarylates measured in there solvents generally have the same range.

The polyarylates may be prepared in the presence of materials such as molecular weight regulators, antioxidants, and the like.

The polarylates obtained by the process of this invention may be used together with the well-known additives such as plasticizers, pigments, lubricating agents, mold release agents, stabilizers, inorganic fillers, and the like. These polyarylates may also be blended with other polymers.

EXAMPLES

The following examples serve to give specific illustrations of the practice of this invention but they are not intended in any way to limit the scope of this invention. In these examples, all parts and percentages are on a weight basis unless otherwise specified.

EXAMPLE 1 Preparation of Prepolymer

The apparatus used herein consisted of a 500 ml round bottom flask fitted with a nitrogen inlet, mechanical stirrer, a vacuum jacketed vigreux column connected to a distillation head and collector flask. 124.8 grams of bisphenol-A diacetate, 33.2 grams of isophthalic acid, 33.2 grams of terephthalic acid, and 63 grams of diphenyl ether were added to the flask. The reaction mixture was purged with nitrogen for about 20 minutes. The reaction mixture was then heated to about 275° C. by immersion of the apparatus in a heating medium. Acetic acid started to distill when the temperature reached about 260° C. The reactants were maintained at 275° C. for 2 hours. The temperature was then raised to about 290°-295° C. and the reactants maintained at this temperature for 2 hours. No apparent distillation of acetic acid was observed during the last hour. A thick yellow product formed. This was allowed to cool to ambient temperature.

Approximately 3 grams of the product was dissolved in methylene chloride (approximately 10 percent solids) and coagulated in isopropanol. The resultant material which was in the form of a fluff was washed with isopropanol two times and then dried at 120° C. (for 24 hours at <1 mm Hg pressure). The reduced viscosity of this polymer was measured in chloroform (0.50 gm/100 ml) at 25° C. and found to be 0.25 dl/gm.

Preparation of Polymer

To a test tube (25 by 200 mm.) fitted with a vacuum adapter, 6 grams of the prepolymer as prepared above was added. The pressure in the test tube was reduced to <0.4 mm Hg. After two minutes at ambient temperature, the test tube was heated to 345°-350° C. and the prepolymer was maintained at this temperature for 30 minutes. The test tube was allowed to cool to ambient temperature. A polymer was recovered by breaking the test tube. The polymer had a deep yellow color. The reduced viscosity of this polymer was measured in chloroform (0.50 gm/dl) at 25° C. and found to be 0.70 dl/gm.

Table I shows the weight in grams of the diphenyl ether used, the weight percent of diphenyl ether used, based on the polymer produced, and the reduced viscosities of the prepolymer and polymer formed.

EXAMPLES 2 TO 6

The procedure as described in Example 1 for forming a prepolymer and polymer was exactly repeated in Examples 2 to 6 except that in forming the prepolymer, the amounts of diphenyl ether shown in Table I were charged to the flask.

Table I shows the weight in grams of the diphenyl ether used, the weight percent of diphenyl ether used, based on the polymer produced, and the reduced viscosities of the prepolymer and polymer formed.

                  TABLE I                                                          ______________________________________                                         Effect of Diphenyl Ether on the Reduced Viscosity                              of the Polyarylate Produced                                                    Diphenyl       Reduced                                                         Ether,         Viscosity                                                       Amount Used    of Prepolymer                                                                              Reduced Viscosity                                   Example                                                                               (gm)    Wt. %   (dl/gm)   of Polymer (dl/gm)                            ______________________________________                                         2      0       0       0.28      0.41                                          3      7       5       0.22      0.57                                          4      16      10      0.28      0.63                                          5      25      15      0.20      0.69                                          1      63      35      0.25      0.70                                          6      435     85      0.07      <0.20                                         ______________________________________                                    

The results in Table I show that without using diphenyl ether, the reduced viscosity of the polyarylate polymer produced is only 0.41 (Example 2). When diphenyl ether is used in amounts of from 5 to 35 weight percent (Examples 3 to 5 and 1), the polyarylate polymer produced has a reduced viscosity in the range of 0.57 to 0.70. However, when diphenyl ether is used in large amounts of 85 weight percent (Example 6) the polyarylate polymer produced has an unacceptable reduced viscosity of less than 0.20 dl/gm.

EXAMPLE 7

The procedure as described in Example 1 for forming a prepolymer was exactly repeated except that 128.4 grams of bisphenol-A diacetate, 66.4 grams of isophthalic acid, and 63 grams of diphenyl ether were charged to the flask. The prepolymer formed had a reduced viscosity of 0.26 dl/gm. A homoisophthalate polymer was formed by the procedure as described in Example 1. The polymer had a reduced viscosity of 0.71 dl/gm.

EXAMPLE 8

The procedure as described in Example 1 for forming a prepolymer was exactly repeated except that 128.4 grams of bisphenol-A diacetate, 49.8 grams of terephthalic acid, 16.6 grams of isophthalic acid and 57 grams of diphenyl ether were charged to the flask. The prepolymer formed had a reduced viscosity of 0.11 dl/gm. A polyarylate polymer was formed by the procedure as described in Example 1. The polymer had a reduced viscosity of 0.80 dl/gm.

EXAMPLE 9

The reactor system consisted of a hot oil heated one gallon reactor fitted with a nitrogen inlet, mechanical agitator, and fractionating column (packed with ceramic saddles) connected to an overhead take-off device consisting of a condenser and a receiver.

The reactor was charged 1200 grams of Bisphenol-A diacetate, 319.1 grams of isophthalic acid, 319.1 grams of terephthalic acid and 740 grams of diphenyl ether (35 weight percent based on the polymer produced). The reactor system was purged with nitrogen for 20 minutes and then the heater turned on to raise the temperatures of the reactor to about 280° C. (the oil heater was set at about 300° C.). Acetic acid started to distill when the temperature reached about 260° C. Acetic acid distillation was followed by measuring the level in the receiver. After about 3.0 hours at 280° C., the power draw on the agitator began to increase which indicated a viscosity increase. The reaction was terminated after 5.5 hours at reflux by discharging the contents of the reactor under nitrogen. The reaction product was allowed to cool to room temperature. The reaction product was ground to articles having an average size below 1/4 inch and stored in an oven at 50°-60° C., for about 10-15 hours under a vacuum of 75 mm Hg. The polymer was isolated by feeding the reaction product to a single screw two vent extruder and flashing off the solvent. The barrel temperature of the extruder was 325° C., the first vent was under a vacuum of about 500 mm Hg, and the second vent was under a vacuum of about 15-20 mm Hg. The residence time of the polymer in the extruder was 2-5 minutes. The polymer had a reduced viscosity of 0.63 dl/g as measured in chloroform (0.50 gm/100 ml) at 25° C.

EXAMPLE 10

The procedure of Example 9 was exactly repeated except that 918 grams of diphenyl ether (40 weight percent based on the polymer produced) was charged to the reactor instead of 740 grams and the reaction time was 6.5 hours instead of 6.0 hours. The polymer produced had a reduced viscosity of 0.68 dl/g as measured in chloroform (0.5 gm/100 ml) at 25° C.

EXAMPLE 11

This Example describes the preparation of a polyarylate polymer in a one-step process starting with bisphenol-A, acetic anhydride, isophthalic and terephthalic acids, and diphenyl ether without isolating the bisphenol-A diacetate.

The reactor system, as described in Example 9, was used herein. The reactor was charged with 877.0 grams of bisphenol-A, 852.8 grams of acetic anhydride, 319.1 grams of isophthalic acid, 315.1 grams of terephthalic acid and 590 grams of diphenyl ether 30 weight percent based on the polymer produced. The reactor system was purged with nitrogen for 20 minutes and the heater turned on to raise the temperature to 150° C. The reactants were maintained at 150° C. for 1.5 hours under reflux conditions. The temperature was raised to about 280° C. The removal of acetic acid by distillation was started and continued until 320 grams of acetic acid was collected. The polymerization was then carried out according to the procedure and for the times and temperatures as described in Example 9. The polymer was recovered, ground and isolated in an extruder by the procedures as described in Example 9.

The polymer had a reduced viscosity of 0.61 dl/g as measured in chloroform (0.50 gm/100 ml) at 25° C.

EXAMPLE 12

This Example describes the preparation of a copolymer according to the procedures of this invention.

Preparation of Prepolymer

The apparatus described in Example 1 was used herein. The 500 ml round bottom flask was charged with 62.4 grams of bisphenol-A diacetate, 38.8 grams of hydroquinone diacetate, 33.2 grams of isophthalic acid, 33.2 grams of terephthalic acid and 60.0 grams of diphenyl ether (30 weight percent based on the polymer produced). The procedure described in Example 1 for forming the prepolymer was used. The prepolymer formed had a reduced viscosity of 0.33 dl/gm as measured in chloroform (0.50 gm/100 ml) at 25° C.

Preparation of Copolymer

A copolymer was formed from the prepolymer by the procedure as described in Example 1. The amorphous copolymer formed was not soluble in chloroform. The reduced viscosity of the copolymer was 0.79 dl/gm as measured in p-chlorophenol (0.20 gm/100 ml) at 49° C. 

What is claimed is:
 1. A process for preparing a polyarylate having a reduced viscosity of from about 0.5 to greater than 1.0 gl/gm, which process comprises reacting:(a) at least one diester derivative of a dihydric phenol having the following formula: ##STR3## wherein R is independently selected from an alkyl radical having from 1 to about 6 carbon atoms, or cycloalkyl having from 4 to about 7 carbon atoms, y is independently selected from alkyl groups of 1 to 4 carbon atoms, chlorine, or bromine, z independently has a value of from 0 to 4, inclusive, and R' is independently selected from a divalent saturated aliphatic hydrocarbon radical having 1 to 8 carbon atoms, a cycloalkylene or cycloalkylidene radical having up to and including 9 carbon atoms, O, S, SO, SO₂, CO, x is 0 or 1; with (b) at least one aromatic dicarboxylic acid, in the presence of from about 10 to about 60 weight percent, based on the polyarylate produced, of a diphenyl ether compound, at a temperature of from about 260° to about 350° C., said reaction being conducted in the absence of catalyst.
 2. A process as defined in claim 1 wherein the diester derivative of a dihydric phenol has the following formula: ##STR4##
 3. A process as defined in claim 2 wherein each z is
 0. 4. A process as defined in claim 1 wherein the aromatic dicarboxylic acid is a mixture of isophthalic acid and terephthalic acid.
 5. A process as defined in claim 4 wherein the isophthalic acid to terephthalic acid ratio in the mixture is about 20:80 to about 100:0.
 6. A process as defined in claim 1 wherein the diphenyl ether is substituted with alkyl groups, chlorine, bromine, or any substituent which does not interfere with the polyarylate forming reaction.
 7. A process as defined in claim 1 wherein the polyarylate produced has a reduced viscosity of from about 0.5 to about 0.8.
 8. A process as defined in claim 1 wherein the diphenyl ether is present in an amount of from about 25 to about 40 weight percent.
 9. A process as defined in claim 1 wherein the temperature is between about 275° to about 295° C.
 10. A process for preparing a polyarylate having a reduced viscosity of from about 0.5 to greater than 1.0 dl/gm which process comprises reacting:(a) an acid anhydride derived from an acid containing from 2 to 8 carbon atoms; (b) at least one dihydric phenol having the following formula: ##STR5## wherein Y is independently selected from alkyl groups of 1 to 4 carbon atoms, chlorine or bromine, z independently has a value of from 0 to 4, inclusive, R' is independently selected from a divalent saturated hydrocarbon radical having 1 to 8 carbon atoms, a cycloalkylene or cycloalkylidene radical having up to and including 9 carbon atoms, O, S, SO, SO₂, CO, x is 0 or 1; and (c) at least one aromatic dicarboxylic acid, in the presence of from about 10 to about 60 weight percent, based on the polyarylate produced, of a diphenyl ether compound, at a temperature of from about 260° to about 350° C., said reaction being conducted in the absence of a catalyst for the dihydric phenol and carboxylic acid.
 11. A process as defined in claim 10 wherein the acid anhydride is acetic anhydride.
 12. A process as defined in claim 10 wherein the dihydric phenol has the following formula: ##STR6##
 13. A process as defined in claim 12 wherein each z is
 0. 14. A process as defined in claim 10 wherein the aromatic dicarboxylic acid is a mixture of isophthalic acid and terephthalic acid.
 15. A process as defined in claim 14 wherein the isophthalic acid to terephthalic acid ratio in the mixture is about 20:80 to about 100:0.
 16. A process for preparing a polyarylate having a reduced viscosity of from about 0.5 to greater than 1.0 dl/gm, which process comprises the following steps:I. forming a polyarylate prepolymer having a reduced viscosity of from about 0.1 to about 0.4 dl/gm, by reacting:(a) at least one diester derivative of a dihydric phenol having the following formula: ##STR7## wherein R is independently an alkyl radical having from 1 to about 6 carbon atoms or cycloalkyl having from 4 to about 7 carbon atoms, y is independently selected from alkyl groups of 1 to 4 carbon atoms, chlorine or bromine, z independently has a value of from 0 to 4, inclusive, and R' is independently selected from a divalent saturated aliphatic hydrocarbon radical having 1 to 8 carbon atoms, a cycloalkylene or cycloalkylidene radical having up to and including 9 carbon atoms, O, S, SO, SO₂, CO, x is 0 or 1; with (b) at least one aromatic dicarboxylic acid, in the presence of from about 10 to about 60 weight percent, based on the polyarylate produced, of a diphenyl ether compound at a temperature of from about 260° to about 350° C., said reaction being conducted in the absence of catalyst; and II. heating the prepolymer so formed at a temperature of from about 300° to 350° C. for a period of time sufficient to form the polyarylate having a reduced viscosity of from about 0.5 to greater than 1.0 dl/g.
 17. A process as defined in claim 16 wherein the prepolymer is heated in step (II) in a vented extruder under vacuum. 